Conductor terminals



Nov. 12, 1957 F. KLUMPP, JR

CONDUCTOR TERMINALS Filed May 9, 1956 INVENTOR. F'Ennmnwo KLuMPP, d9- BY /77 7 OR/VE Y nited States Patent CONDUCTOR TERMINALS Ferdinand Klumpp, Jr., Union, N. J. Application May 9, 1956, Serial No. 583,869

Claims. (Cl. 339-276) My invention relates to conductor terminals useful in connectors such as electric cord plugs and the like and more particularly to such terminals of the blade type, formed from flat stock.

In connectors in which the body of the plug or cap, for example, is molded around the conductor terminals or blades, it is desirable in some cases that the terminals be constructed to facilitate use of the terminal and the conductor secured thereto in constructions in which the terminal and the conductor emerge at an angle to each other from the body of the moldedplug.

Pressure exerted on conventional blades during moldingoperations causes the blades to break at those portions of the terminal between the conductor receiving sleeve and the remainder of the blade, since these portions, because of the way the blades are formed, are the narrowest and hence the weakest part of the terminal. Furthermore, because this is the thinnest part and is only of single thickness, the terminal blade is limited in the amount of current that it can carry.

It is also desirable to provide a construction of conductor terminal which is simple in construction and which facilitates formation of the terminal from the raw stock. Another desirable objective is to reduce the scrap during forming, thus making more metal available for the terminal for increasing its strength and its current-carrying capacity.

Where heavy conductors for carrying large currents are used, it is desirable to have strong and heavy conductorengaging elements to securely fasten the conductor to the terminal and to have an optimum transverse section to increase current-carrying capacity.

Another desirable feature of terminals of the folded variety is to provide a construction in which the folded portions are securely locked together with the conductor attached prior to molding into the finished connector.

It is therefore an object of my invention to provide an improved conductor terminal which facilitates use in connectors of the angle variety although not limited thereto.

A further object of my invention is to provide a terminal which is not subject to rupture during molding operation A still further object of my invention is to provide an improved terminal which is simple in construction and which facilitates formation of the finished terminal while, at the same time, reducing scrap and increasing the strength of the terminal and its current-carrying capacity.

A further object of my invention is to provide a terminal having improved conductor-engaging means which also act as a locking means for folded type terminals.

Other objects ofrthe invention will appear in the follow ing description.

Briefly, in accordance with my invention, the conductor terminal is first stamped or punched out as an elongated blank comprising two members which are folded over in registry to form the terminal blade. One of the elongated members is provided at its end with a conductorengaging finger or tongue. The other member has punched and formed from its body adjacent one end a tongue or stop member extending normally of the member. The one member has punched and formed from the body adjacent the conductor-engaging finger or tongue extending from the end thereof a second conductor-engaging tongue, both tongues being formed to extend at an angle from the one member and oppositely to the stop member or tongue. The two members are then folded together so that one of the conductor-engaging tongues extends through the aperture from which the stop member was formed. The two conductor-engaging tongues are then formed into loops and pressed against a conductor received between the tongues to lock the conductor to the terminal blade and to lock the two portions of the blade together. A pair of such terminal blades may be connected to pairs of conductors and then molded into a cap or plug.

In the drawing:

Fig. 1 is a perspective partially in section showing terminals made according to my invention utilized in a molded connector or plug of the angle type;

Fig. 2 is a perspective of a terminal blade made according to my invention fastened to a conductor prior to molding in;

Fig. 3 is a plan view of a my invention;

Fig. 4 is a sideelevation of the terminal shown in Fig. 2;

Fig. 5 is a blank showing a step in forming a terminal made according to my invention; and

Fig. 6 is a side elevation showing a later step in the formation of a terminal made according to my invention.

A terminal made according to my invention as best shown in Figs. 2, 3, and 4, includes an elongated member 10 having adjacent one end thereof a rectangularly-shaped aperture 11, partially formed by blanking or punching out a part and forming a stop member or tongue element 12 from the metal. The stop element 12 extends normally of the member It at the periphery of the aperture.

A second elongated member 13, which can be formed by a folded-over portion of an elongated blank, is provided with a conductor-engaging tongue 14 at one end thereof adjacent the apertured end of the first elongated member 10. It is folded up against the end of member 10 to overlie the end of member 10. A second tongue 15 formed from the body of the elongated member 13 is formed to extend through the aperture 11. Thus, the tongues 14 and 15 are oppositely disposed and as shown in Figs. 1 and 2 are folded over into loops 14', 15' to engage the conductor 21 and secure it firmly against the terminal at the same time locking the two folded-over portions 10 and 13 against each other prior to being molded into the plug 20.

Steps in the formation of a blade terminal made in accordance with my invention are illustrated in Figs. 5 and 6. As shown, the terminal may be formed from flat stock with the portions 10 and 13 extending oppositely from each other with the portion 13 provided with the tongue 14 extending from one end thereof. The other tongue 15 is formed by a punch and die as is the stop member 12, the material 12 being removed as scrap. The two portions 10 and 13 are then subjected to the action of the dies which position the tongues and stop member as indicated in Fig. 6 after which a folding operation takes place to provide the terminal shown in Figs. 3 and 4.

The conductors are then secured to the terminal members by forming the tongues 14 and 15 over and against the conductor to securely fasten the conductor without terminal made according to the use of solder to the terminal member after which the,

terminals may be molded into a plug to provide the connector 20 as shown in Fig. 1.

As illustrated in Figs, 1 and 2, the terminal blades and the conductors secured thereto are "at 9 to" each other. If a straight through arrangement is desiredfthe conductor may 'be given a 90 turn so that it extends parallel to the bladeand'along o'ne edgeand oppositely to the terminal. It is of course apparent that angles other than'90 may be employed. r

:It'will 'be observed that little scrap results from the constructionem'ployed leaving more metal to provide a strong and rugged terminal and to provide a larger cross section of metal for carrying heayy currents. h The tongues 14 and 15 can be varied in'width andlength to engage various sizes of conductors -ofthe solid type 'or of the strand type. It is obvious that the construction facilitates so-called right angle assembly for plugs-or connectors in which the conductors emerge from "the connectorat an angle to the terminals. 7 t

- "Since the two members It) and 13 areboth electrically connected to the tongues 14 and 15, they are available for carrying current and hence since a double thickness of metal is provided along the entire length of the terminal, which is not the usual practice, much heavier currents can be carried by the terminal. it is of course obvious that, if desired, one 'or the other of the members 10 or 13 could be formed with a slight bulge orbow to provide a spring action.

Furthermore, since there are no thinned-out portions such as a single thickness between the terminal and the sleeve which normally receives the conductor, fracture of the terminal during molding is substantially completely eliminated. The tongues 14 and 15, in addition toproviding a firm, rigid contact of large area for the conductor, also serve to lock the two portions of the conductor terminal together/thus further-insuring no deformation or rupturing during molding operations.

The structure is simple and reduces the'number of steps in formation to a minimum requiring merely punching, folding and bending without the necessity of forming sleeves with a twisting action of the conductor-engaging parts as required in other types of terminals, thus preventing weakening of the conductor-engaging portions.

If desired, the stop member 12 could employ all of the metal from which the aperture 11 is formed. This would result in a longer tongue. Likewise, it could be formed to extend from the same side as tongues 14 and Has shown in Fig. 5 and when folded over against the part 13, extend downwardly through the aperturetlS which results from the punching out and forming of the tongue 15 from the metal body of member 13.

I claim:

1. A conductor terminal including a first elongated member having an aperture adjacent one end thereof and a tongue extending at an angle to said member at the periphery of said aperture, a second elongated member registering with said first elongated member and in'contact therewith, said second elongated member having a first'conductor-engaging tongue at an angle thereto adjacent the apertured end of said first member and overlying the endof said first elongated member, said second elongated member having a second conductor-engaging tongue formed from the body of said second elongated member and extending at an angle thereto and through'said aperture at the periphery thereof and oppositelydisposed to said first conductor-engaging tongue, said conductor-engaging tongues being adapted to be formed into loops to engage a'conductor and force it into contact'with said elongated members.

2. A conductor terminal including a first elongated member having an aperture adjacent one end thereof and a stopmember extending at an angle to said member at theperiphery of said aperture, a second elongated memberr'egistering with said first elongated member'and 3. A conductor terminal formed from fiat stock and including a pair of elongated elements secured together at one end and registering withand' in'"contact with each other, one of saidelements having an 'aperture adjacent one end thereof, the other of said elements including a pair of tongue members adjacent the apertured end of said one element, said tongue members being positioned at an angle to said elements, one of said tongue members extending from the end of said other element and overlying the end of said one. element and the other of said tongue members extending through the aperture of said one element,'said tongue members being adapted to be formed into oppositely disposed loops'engaging a conductor and the apertured endof. the first element to maintain said conductor and said elements in locked relationship. j

4. A conductor terminal including a pair of elongated elements registering with and in contact with each other, one of said elements having an aperture adjacent one end thereof, a stop member extending from said apertured member and at'an angle thereto at the periphery of'saidaperture, the other of said elements including a pair of tongue members adjacent the' apertured end of said one element, said tonguemembersbeing positioned at'an'angle to said elements, one of said tongue members extending beyond the ends of said elements and the other of said tongue members extending through thej'aperture 'of said one element, said tongue members adapted to be formed into oppositely disposed loops for engaging a conductor. v

5. A conductor terminal includingan elongated member having an aperture adjacent one end thereof and a stop member'extending at an angle .to'said member at the periphery of said aperture, a second elongated member registering with said first elongated member and in contact therewith, said second elongated member having a first conductor-engaging tongue at an angle thereto adjacent the apertured end'of said first member, said second-elongated member having a second tongue extending at' an angle theretoand through said aperture and oppositely disposed to said first tongue, said tongues being adapted to be formed into loops to engage a conductor.

6. A conductor terminal including afirst elongated element having a rectangular. aperture adjacent one end thereof, the longer axis of said aperture lying along'the longitudinal axis of said ele'rnentfa tongue formed from part of the material removed'to form said aperture and extending from the periphery of the-aperture at an angle to said element to provide'a stop member, a second elongated element in contact with the firstelongatedelement and having a first tongue element extending from an end thereof at an angle thereto and overlying the end adjacent said aperture of said first-element, and a second tonguev element'extending through said aperture-and opposite to said stop member and at an'angleto "said first element, said tongue elementsbeing oppositely'disposed andadapted to be folded toward each otherinto oppositely disposed loops for firmly engaging a conductor extending transversely of said elongated elements and to lock said-elongated elements together. I Y

7. A conductor terminal'includi'nga firstelongated element having a rectangular aperture adjacent one'en'd thereof, the longer axis of said aperture lying along the longitudinal axis of said element, a second elongated element in contact with and in registry with the first elongated element and having a tongue memberextending from one end thereof at an angle thereto and overlying the end adjacent said aperture of said first element, and a second tongue member extending through said aperture adjacent the periphery thereof at an angle to said first elongated element, said tongue members being oppositely disposed and adapted to be folded toward each other into oppositely disposed loops for firmly engaging a conductor extending transversely of said elements and to lock said elements together.

8. A connector including a molded plug of angular shape, a plurality of conductor terminals and conductors connected thereto molded within said connector, each of said conductor terminals including a first elongated element having a rectangular aperture adjacent one end thereof, the longer axis of said aperture lying along the longitudinal axis of said element, a tongue formed from a part of the material removed to form said aperture and extending from the periphery of the aperture at an angle to said element to provide a stop member, a second elongated element in contact with the first elongated element and having a tongue element extending from the end thereof at an angle thereto and overlying the end adjacent said aperture of said first element, and a second tongue element extending through said aperture and opposite to said stop member and at an angle to said first element, said tongue elements being oppositely disposed and folded toward each other into oppositely disposed loops and firmly engaging the conductor extending transversely of said element and locking said elements together, said conductor terminals and said conductors extending from the body of said connector at an angle to each other.

9. A connector including a molded plug of angular shape, a plurality of conductor terminals and conductors connected thereto molded within said connector, each of said conductor terminals including a first elongated element having an aperture adjacent one end thereof, a tongue formed from a part of the material removed to form said aperture and extending from the periphery of the aperture at an angle to said first element to provide a stop member, a second elongated element in contact with the first elongated element and having a tongue element extending from the end thereof at an angle thereto and overlying the end adjacent said aperture of said first element, and a second tongue element extending through said aperture adjacent the periphery thereof and at an angle to said first element, said tongue elements being oppositely disposed and folded toward each other into oppositely disposed loops and firmly engaging the conductor extending transversely of said element and locking said elements together, said conductor terminals and said conductors extending from the body of said connector at an angle to each other.

10. A connector including a molded plug, a plurality of conductor terminals and conductors connected thereto molded within said connector, said conductor terminals being formed of flat stock, each of said conductor terminals including a first elongated element having a rectangular aperture adjacent one end thereof, the longer axis of said aperture lying along the longitudinal axis of said element, a tongue formed from a part of the material removed to form said aperture and extending from the periphery of the aperture at one end thereof and at an angle to said element to provide a stop member, a second elongated element registering with and in contact with the first elongated element and having a tongue element extending from the end thereof at an angle thereto and overlying the end adjacent said aperture of said first element, and a second tongue element extending through said aperture adjacent the periphery thereof and opposite to said stop member and at an angle to said first element, said tongue elements being oppositely disposed and folded toward each other into oppositely disposed loops and firmly engaging the conductor extending transversely of said element and locking said elements together, said conductor terminals and said conductors extending from the body of said connector.

References Cited in the file of this patent UNITED STATES PATENTS 2,309,311 Gronsgal Jan. 26, 1943 2,371,494 Benander Mar. 13, 1945 2,439,767 Wermine Apr. 13, 1948 

